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Particle durch
simulation withKlicken
Rockybearbeiten
DEM
CADFEM GmbH - Part 1

Luca Benvenuti

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Agenda

• DEM: Theory and Applications

• DEM: Calibration and Customization

• DEM: More Efficient Processes

• DEM: Longer Machine Life

• Multi-GPU Solver

• Non-Spherical Particle Shapes

• Fully integrated with ANSYS Software: Workbench & Mechanical

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DEM: Theory and durch Klicken bearbeiten
Applications

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DEM: Granular Material

• Granular material
• Solid macroscopic material
• Dissipate energy by interaction, mostly
friction

• Many industries deal with particles

Ship loading
• Mining
• Pharmaceutical
• Agriculture
• Cement
• Transport
• Chemical

• Discrete element method is used to

model granular material
• Particulate systems are difficult to
measure
• Method to simulate a large number of
discrete objects
• Classic mechanics wikipedia

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DEM: Predicting Particle Motion in Time

• Force and Torque balance for each particle

• Example: particle falling:

Time = t, åF = F body = mg

g Time = t + Dt, åF = F body = mg

Time = t + 2Dt, åF = F body + F surface = mg+ F(t)contact

wall Time = t + 3Dt, åF = F body = mg

F = Force, m= mass, a = acceleration, g = acceleration due to gravity
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DEM: Contact forces

• Soft-sphere method is the most

common, Cundall and Strack (1979)

• Particles can have a minimum

overlap

d
• Overlap is used to calculate elastic,
plastic and frictional forces
• Normal and tangential directions
F surface,norm ~ (d , d&, L, E, COR...)
F surface,tan ~ (d , d&, L, m , m ,....)
• Explicit time integration
s d

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DEM: Contact Models

• Normal Forces
• Hysteretic Linear Spring, Linear Spring Dashpot, Hertzian Spring
Dashpot

• Tangential Forces
• Linear Spring Coulomb Limit, Coulomb Limit, Mindlin-Deresiewicz

• Adhesive Forces
• Constant, Linear, Leeds, Hertzian Spring Dashpot with JKR
Cohesion

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DEM: Calculation Loop
START: Make geometry, create particles, create
neighbor list and contact list

DETERMINE FORCES & MOMENTS: Calculate sum of ALL forces & moments
(Euler’s equation) acting on each particle

åF net = F body + F surface = ma

(Euler’s rotational equations of motion not shown for clarity)

INTEGRATE STATES: Integrate in time to find new position

å Fnet
DV = ò m dt; Vnew = Vold + DV
Dx = ò V new dt; xnew = xold + Dx
V = velocity, x = position, dt = time step

No END: Simulation end time or Yes

STOP
particles out of range?

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 DEM: Industrial processes

• Separation / Mixing • Transport

Source: https://en.wikipedia.org/wiki/Mechanical_screening Source: http://www.mechanicalengineeringblog.com/tag/bucket-

elevator-how-it-works/

• Size reduction / Granulation • Storage

Source: https://en.wikipedia.org/wiki/Crusher Source: https://en.wikipedia.org/wiki/Silo

https://en.wikipedia.org/wiki/Ball_mill

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DEM: How can modelling help?

• Increase equipment life and capacity

• Eliminate blockages

• Decrease product degradation

• Reduce equipment noise, dust and power

• Define material trajectories

• Optimize belt tracking

• Minimize wear and maintenance

• …. and so on

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DEM: Applications
Wood chips (biomass handling) Tablets (pharmaceutical tablet coating)

Rocks (truck dump) Wet and sticky ore (chute transfer in mining)

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DEM: Applications

• Eliminates need for external Multi-Body

Dynamic Coupling (Unless geometry
interactions are essential)
• Any geometry in Rocky can be a Free
Body (motion can be constrained and
boundary loads can be specified)
• Ballasted Layer Deformation
• Powder Compaction
• Building in Landslide

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DEM: Applications: e.g. Excavator

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DEM: Applications: e.g. Ring Pan Mixer

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DEM: Applications: Dust Flow

• Airflow (Lattice-Boltzmann)
• Simulation of a transfer chute with
airflow vectors enabled:
• Show how dust and gas is affected • Simulation of a transfer chute with
by particle flow NO airflow vectors enabled

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DEM: durch
Calibration and Klicken bearbeiten
Customization

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DEM: Calibration

• Determination of the relevant

parameters in experiments

• Parameter identification by
matching of real & virtual
experiment

Quelle: TUNRA BULK SOLIDS

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 DEM: Calibration and Customization

• Calibrate material data

• Automatic process
• Consider statistics

• Customized results
• Export particles position and orientation
• Automatic generation of void-volume for CFD

Exported particle results

ROCKY results
Rebuild ROCKY results in CAD

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DEM: durch
More Efficient Klicken bearbeiten
Processes

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DEM: More Efficient Processes: Plow Mixer

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DEM: More Efficient Processes: Plow Mixer

• GUI based post-processing

• Qualitative analyses:
• 3D visualization
• Animations
• Plots by color
• Quantitative analyses:
• XY plots
• time plots
• histograms

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DEM: durchLife
Longer Machine Klicken bearbeiten

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DEM: Longer Machine Life: Transfer Chutes Boundary Surface Wear

• Wall forces due to particles interactions (instantaneous and time average)

are calculated

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DEM: Longer Machine Life: Transfer Chutes Boundary Surface Wear

Mean Shear • Shear Intensity X Belt Width • Impact Intensity X Belt Width
Power (W/m2)

Shear Intensity (W/m2)

Impact Intensity (W/m2)

Belt Width (m)

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Multi-GPU Solver durch Klicken bearbeiten

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Multi-GPU Solver: Flexible Operating System

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Multi-GPU Solver: Tablet Coater

• Shared-parallel memory for both GPU and CPU

• Commercial scale tablet coater rotating at 10 RPM Gaming cards Computing cards
• 242,000 custom convex particles with 222 vertices each
• Advances in DEM Computing Which Improve Predictive Capability for Processes, AIChE 2016, Stomata et al.

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Multi-GPU Solver: High Shear Wet Granulation

• Scale up of high shear wet granulation

• Advances in Discrete Element Modeling of high-shear wet granulation process using Rocky-DEM,
AIChE 2016, Pandey et al.

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Multi-GPU Solver: High Shear Wet Granulation

• Scale up of high shear wet granulation

• Suggestion: each 500k particles à use 1 GPU (e.g. 2MM à 4 GPU)

• 10 L granulator wall-clock-time-speed-up VS Particles-number-speed-up Relation

Scalability (and memory) for large particle numbers on multi-GPU

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Multi-GPU Solver: SAG Mill

• 9.8m SAG mill (Section: 0.5 m)

• Fill: 25% (20% Ball)
• Speed: 10.3 RPM

• 1MM spherical particles

• Ore particles (0.17 – 0.01 m)
• Ball particles (0.10 – 0.055 m)

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Multi-GPU Solver: V-Blender

• V-Blender is filled (Top-Bottom) and rotates at 10 RPM

• Two particle groups of diferent materials are mixed
• 300,000 spherical particles

Gaming cards Computing cards

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Titelmasterformat durchShapes
Non-Spherical Particle Klicken bearbeiten

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Non-Spherical Particle Shapes

• Default particle shapes in Rocky:

Spherical Faceted Rounded Rounded Rounded Briquette

Cylinder Polygon Polyhedron
• Rocky shape examples:

rock rice capsule pill

potato pea rod chip

orange barley metal coal

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Non-Spherical Particle Shapes: Does Shape Really Matter?

• Glued spheres • Polyhedral shape

Almond Shape Tablet Representation

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Non-Spherical Particle Shapes: STL import

• Scan any shape and import it into Rocky:

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Non-Spherical Particle Shapes: Improved Concave Particle Simulation

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Non-Spherical Particle Shapes: Improved Concave Particle Simulation

• Concave shapes:
Thin Potato Chip

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Non-Spherical Particle Shapes: Real case

• Screening/sorting
• Real particle
• Vibration movement

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Fully integrated with Klicken
ANSYS bearbeiten
Software
Workbench & Mechanical

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ROCKY and ANSYS: Workbench integration

• Geometry parameterization using

SpaceClaim (CAD)

• ROCKY parameters exposed into

ANSYS Workbench environment

• Automated project-level update

mechanism

• DOE/Optimization/Sensitivity
analysis using OptiSLang or Desing
Explorer

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ROCKY and ANSYS: Mechanical Coupling

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ROCKY and ANSYS: Mechanical Coupling – Static Structural

• Rocky calculates the particle forces and the pressure (force over triangle
area) on the boundary. The pressures components are then exported to
Workbench Mechanical.

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ROCKY and ANSYS: Mechanical Coupling – Static Structural

• Stresses and vibration analyses of a

screen in ANSYS
• Inputs come from Rocky simulation

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ROCKY and ANSYS: Mechanical Coupling – Static Structural

ANSYS Mechanical results

ANSYS SpaceClaim

Rocky results
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ROCKY and ANSYS: Mechanical Coupling – Transient Structural

• When there is boundary’s motion,

Rocky translate and rotate the loads
from the atual position to the initial
position, so in WB Mechanical the
strututure remais stopped while the
loads moves.
• User defines the output frequency and
the time range to export to the
Mechanical
• In Mechanical, user has to setup the
imported pressure to Components and
fill the Tabular Data

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FULLY INTEGRATED with ANSYS tools

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